Table saw with actuator module

ABSTRACT

A power tool in one embodiment includes a swing arm assembly movable along a swing path between a first swing arm position and a second swing arm position, a latch pin pivotable between a first position and a second position, an actuator module configured to receive a plurality of actuators, a first actuating module position within the actuator module configured to align a first of the plurality of actuators with a strike plate on the swing arm assembly, a loader configured to bias a second of the plurality of actuators from a second actuating module position within the actuator module toward the first actuating module position, and a control system configured to actuate each of the plurality of actuators positioned in the first actuating module position to force the swing arm assembly away from the first swing arm position and toward the second swing arm position.

Cross-reference is made to U.S. Utility patent application Ser. No.[Attorney Docket No. 1576-0626] entitled “Table Saw with Dust Shield” byChung, which was filed on Aug. 26, 2009; U.S. Utility patent applicationSer. No. [Attorney Docket No. 1576-0627] entitled “Table Saw withPositive Locking Mechanism” by Chung et al., which was filed on Aug. 26,2009; U.S. Utility patent application Ser. No. [Attorney Docket No.1576-0628] entitled “Table Saw with Belt Stop” by Chung, which was filedon Aug. 26, 2009; U.S. Utility patent application Ser. No. [AttorneyDocket No. 1576-0629] entitled “Table Saw with Alignment Plate” by Chunget al., which was filed on Aug. 26, 2009; U.S. Utility patentapplication Ser. No. [Attorney Docket No. 1576-0630] entitled “Table Sawwith Swing Arm Support” by Chung et al., which was filed on Aug. 26,2009; U.S. Utility Patent Application Ser. No. [Attorney Docket No.1576-0631] entitled “Table Saw with Mechanical Fuse” by Oberheim, whichwas filed on Aug. 26, 2009; U.S. Utility Patent Application Ser. No.[Attorney Docket No. 1576-0632] entitled “Table Saw with PressureOperated Actuator” by Fischer et al., which was filed on Aug. 26, 2009;U.S. Utility patent application Ser. No. [Attorney Docket No. 1576-0634]entitled “Table Saw with Reset Mechanism” by Groth et al., which wasfiled on Aug. 26, 2009; U.S. Utility patent application Ser. No.[Attorney Docket No. 1576-0635] entitled “Table Saw with Linkage DropSystem” by Holmes et al., which was filed on Aug. 26, 2009; U.S. Utilitypatent application Ser. No. [Attorney Docket No. 1576-0636] entitled“Table Saw with Ratchet Mechanism” by Chung et al., which was filed onAug. 26, 2009; and U.S. Utility patent application Ser. No. [AttorneyDocket No. 1576-0637] entitled “Table Saw with Actuator Reset Mechanism”by Chung, which was filed on Aug. 26, 2009, the entirety of each ofwhich is incorporated herein by reference. The principles of the presentinvention may be combined with features disclosed in those patentapplications.

FIELD

The present disclosure relates to power tools and more particularly topower tools with exposed shaping devices.

BACKGROUND

A number of power tools have been produced to facilitate forming awork-piece into a desired shape. One such power tool is a table saw. Awide range of table saws are available for a variety of uses. Some tablesaws such as cabinet table saws are very heavy and relatively immobile.Other table saws, sometimes referred to as jobsite table saws, arerelatively light. Jobsite table saws are thus portable so that a workercan position the table saw at a job site. Some accuracy is typicallysacrificed in making a table saw sufficiently light to be mobile. Theconvenience of locating a table saw at a job site, however, makes jobsite table saws very desirable in applications such as generalconstruction projects.

All table saws, including cabinet table saws and job site table saws,present a safety concern because the saw blade of the table saw istypically very sharp and moving at a high rate of speed. Accordingly,severe injury such as severed digits and deep lacerations can occuralmost instantaneously. A number of different safety systems have beendeveloped for table saws in response to the dangers inherent in anexposed blade moving at high speed. One such safety system is a bladeguard. Blade guards movably enclose the saw blade, thereby providing aphysical barrier that must be moved before the rotating blade isexposed. While blade guards are effective to prevent some injuries, theblade guards can be removed by a user either for convenience of usingthe table saw or because the blade guard is not compatible for use witha particular shaping device. By way of example, a blade guard istypically not compatible with a dado blade and must typically be removedwhen performing non-through cuts.

Table saw safety systems have also been developed which are intended tostop the blade when a user's hand approaches or touches the blade.Various stopping devices have been developed including braking deviceswhich are physically inserted into the teeth of the blade. Suchapproaches are extremely effective. Upon actuation of this type ofbraking device, however, the blade is typically ruined because of thebraking member. Additionally, the braking member is typically destroyed.Accordingly, each time the safety device is actuated; significantresources must be expended to replace the blade and the braking member.Another shortcoming of this type of safety device is that the shapingdevice must be toothed. Moreover, if a spare blade and braking memberare not on hand, a user must travel to a store to obtain replacements.Thus, while effective, this type of safety system can be expensive andinconvenient.

Some safety systems incorporating blade braking systems also move theblade below the surface of the table saw once the blade has beenstopped. In this type of system, a latch is typically used to maintainthe blade in position above the table saw surface until the brakingsystem is activated. Some of these systems incorporate a single useactuator which must be replaced each time the actuator is fired.

In view of the foregoing, it would be advantageous to provide a powertool with a safety system that does not interfere with shapingprocedures. A safety system that did not damage the blade or othershaping device when the safety system is activated would be furtheradvantageous. A further advantage would be realized by a safety systemthat could be repeatedly activated without the need for replacementparts each time the system is activated.

SUMMARY

In accordance with one embodiment, a table saw includes a swing armassembly movable along a swing path between a first swing arm positionwhereat a portion of a shaping device supported by the swing armassembly extends above the work-piece support surface and a second swingarm position whereat the portion of the shaping device does not extendabove the work-piece support surface, a latch pin pivotable between afirst position whereat the latch pin is engaged with the swing armassembly and a second position whereat the latch is not engaged with theswing arm assembly, an actuator module configured to receive a pluralityof actuators, a first actuating module position within the actuatormodule configured to align a first of the plurality of actuators with astrike plate on the swing arm assembly, a loader configured to bias asecond of the plurality of actuators from a second actuating moduleposition within the actuator module toward the first actuating moduleposition, and a control system configured to actuate each of theplurality of actuators positioned in the first actuating module positionso as to cause the latch pin to move from the first position to thesecond position and to force the swing arm assembly away from the firstswing arm position and toward the second swing arm position.

In another embodiment, a power tool includes a work-piece supportsurface, a swing arm assembly movable along a swing path between a firstswing arm position whereat a portion of a shaping device supported bythe swing arm assembly extends above the work-piece support surface anda second swing arm position whereat the portion of the shaping devicedoes not extend above the work-piece support surface, a latch pinmovable between a first position whereat the latch pin is engaged withthe swing arm assembly and a second position whereat the latch is notengaged with the swing arm assembly, an actuator module configured toreceive a plurality of actuators, a first actuating module positionwithin the actuator module configured to align a first of the pluralityof actuators with a portion of the swing arm assembly, a loaderconfigured to bias a second of the plurality of actuators from a secondactuating module position within the actuator module toward the firstactuating module position, and a control system configured to actuateeach of the plurality of actuators positioned in the first actuatingmodule position so as to cause the latch pin to move from the firstposition to the second position and to force the swing arm assembly awayfrom the first swing arm position and toward the second swing armposition.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate various embodiments of the presentdisclosure and together with a description serve to explain theprinciples of the disclosure.

FIG. 1 depicts a top perspective view of a table saw incorporating amitigation system in accordance with principles of the invention;

FIG. 2 depicts a bottom perspective view of the table saw of FIG. 1 withthe housing removed showing a movable carriage mounted on a pivotingframe beneath the work-piece support surface;

FIG. 3 depicts a perspective view of the swing arm assembly of the tablesaw of FIG. 1;

FIG. 4 depicts a partial perspective cross-sectional view of the swingarm assembly of FIG. 3 supported by a latch assembly including a latchhold that is biased against the swing arm assembly;

FIG. 4A depicts a partial perspective cross-sectional view of theactuation module of FIG. 4;

FIG. 4B depicts a perspective view of a stop pad for decelerating theswing arm assembly and substantially preventing the swing arm assemblyfrom rebounding upwardly;

FIG. 5 depicts a partial cross-section view of a swing arm assembly heldin position by a latch pin biased against a latch hold;

FIG. 6 depicts a partial perspective view of the swing arm assembly andlatch assembly of FIG. 1 after the actuator has been actuated therebyforcing the latch pin off of the latch hold such that the swing armassembly moves away from the latch assembly;

FIG. 7 depicts a partial perspective view of the swing arm assembly andlatch assembly of FIG. 1 after the swing arm assembly has cleared thelatch hold allowing the latch hold to be biased into the swing path;

FIG. 8 depicts a partial perspective view of the swing arm assembly andlatch assembly of FIG. 1 after the swing arm assembly has rebounded offof the stop pad and has been captured by a latch hold ledge therebykeeping the shaping device below the surface of the work-piece supportsurface;

FIG. 9 depicts a partial perspective view of the swing arm assembly andlatch assembly of FIG. 1 after the swing arm assembly has rebounded offof the stop pad and has been captured by a secondary latch hold ledgethereby keeping the shaping device below the surface of the work-piecesupport surface;

FIG. 10A depicts a schematic view of a friction ratchet assembly forpreventing the swing arm assembly from rebounding after the swing armassembly has dropped;

FIG. 10B depicts a partial perspective view of a swing arm assemblyincluding a spring-loaded swing arm assembly;

FIG. 10C depicts an enlarged perspective view of a portion of thespring-loaded swing arm assembly of FIG. 4B;

FIG. 10D depicts a schematic view of a swing arm assembly including anover-damped spring-loaded swing arm assembly;

FIG. 10E depicts a partial perspective cross-sectional view of a powertool with a latching pin that does not rotate with the swing armmechanism;

FIG. 11 depicts a partial perspective cross-sectional view of a powertool with a vertical swing arm and a positive locking mechanism;

FIG. 12 depicts a perspective view of the positive locking mechanism ofFIG. 11;

FIG. 13 depicts a partial cross-sectional view of the positive lockingmechanism of FIG. 11 as an actuator pin contacts an actuation ramp in abore extending through the positive locking mechanism;

FIG. 14 depicts a partial cross-sectional view of the positive lockingmechanism of FIG. 11 as a strike plate is exposed to the actuator pin ofFIG. 13 through the bore in the positive locking mechanism;

FIG. 15 depicts a partial cross-sectional view of the positive lockingmechanism of FIG. 11 as the actuator pin of FIG. 13 impacts the strikeplate;

FIG. 16 depicts a partial cross-sectional view of the power tool of FIG.11 as the swing arm assembly contacts a release on a rebound latch;

FIG. 17 depicts a partial cross-sectional view of the power tool of FIG.11 with the swing arm assembly in contact with a latch foot on a reboundlatch for automatically positioning the rebound latch to arrestrebounding of the swing arm assembly off of a stop pad;

FIG. 18 depicts a partial cross-sectional view of the power tool of FIG.11 with the swing arm assembly arrested from rebounding by the reboundlatch;

FIG. 19 depicts a schematic representation of the relative positions ofa shaping tool as a horizontally mounted swing arm and a verticallymounted swing arm move a blade to a location beneath a work-piecesupport surface;

FIG. 20 depicts a perspective view of a positive locking mechanism whichautomatically aligns an actuating ramp with an actuator;

FIG. 21 depicts a cross-sectional view of a positive locking mechanismwith a roller that reduces wear of the mechanism and which can be usedto reduce movement of a latched swing arm assembly;

FIG. 22 depicts a cross-sectional view of a positive locking mechanismwhich can be used to reduce movement of a latched swing arm assembly;

FIGS. 23 and 24 depict a positive locking mechanism which engages a pinin a swing arm assembly and with an actuation ramp extending from thebody of the mechanism, and which rotates about an axis of rotation thatis not parallel to the axis along which an actuator pin moves;

FIGS. 25 and 26 depict a positive locking mechanism which engages arecess in a swing arm assembly and with an actuation ramp defined in thebody of the mechanism, and which rotates about an axis of rotation thatis not parallel to the axis along which an actuator pin moves; and

FIGS. 27 and 28 depict a positive locking mechanism which engages arecess in a swing arm assembly and with an actuation ramp defined in thebody of the mechanism, and which rotates about an axis of rotation thatis parallel to the axis along which an actuator pin moves.

Corresponding reference characters indicate corresponding partsthroughout the several views. Like reference characters indicate likeparts throughout the several views.

DETAIL DESCRIPTION OF THE DISCLOSURE

While the power tools described herein are susceptible to variousmodifications and alternative forms, specific embodiments thereof havebeen shown by way of example in the drawings and will herein bedescribed in detail. It should be understood, however, that there is nointent to limit the power tools to the particular forms disclosed. Onthe contrary, the intention is to cover all combinations of features,modifications, equivalents, and alternatives falling within the spiritand scope of the invention as defined by the appended claims.

Referring to FIG. 1, a table saw 100 is shown. The table saw 100includes a base housing 102 and a work-piece support surface 104. Asplitter 106 is positioned adjacent to a blade 108 which extends fromwithin the base housing 102 to above the work-piece support surface 104.A blade guard (not shown) may be attached to the splitter 106. An angleindicator 110 indicates the angle of the blade 108 with respect to thework-piece support surface 104. A bevel adjust turn-wheel 112 may beused to establish the angle of the blade 108 with respect to thework-piece support surface 104 by pivoting a frame 114 (shown in FIG. 2)within the base housing 102.

A motor 116 which is powered through a switch 118 located on the basehousing 102, is supported by a carriage assembly 120. The carriageassembly 120 and a stop pad 122 are supported by the frame 114. Thecarriage assembly 120 includes a carriage 124 to which the motor 116 ismounted and two guiderails 126/128. The position of the carriage 124along the guiderails 126/128 is controlled by a blade height turn-wheel130 through a gearing assembly 132 and a height adjustment rod 134. Thecarriage 124 fixedly supports a latch assembly 140 and pivotablysupports a swing arm assembly 142.

The swing arm assembly 142, also shown in FIGS. 3 and 4, includes ahousing 144. A strike plate 146 and a rebound plate 148 are mounted onthe housing 144. The housing 144 encloses a power wheel 150 that isdriven by a power shaft 152. The power shaft 152 may be directly drivenby the motor 116 or by a reduction gear. A belt 154 transfers rotationalmovement from the power wheel 150 to a blade wheel 156. A nut 158 isused to affix the blade 108 (not shown in FIGS. 3 and 4 for purpose ofclarity) to the blade wheel 156. A tensioner 160 maintains the belt 154at a desired tension.

With additional reference to FIG. 5, the swing arm assembly 142 alsoincludes a lip 164 and a latch pin 166 which is biased by a spring 168toward a latch hold 170 which is part of the latch assembly 140. In oneembodiment, the latch pin is fixedly attached to the swing arm assembly142. The latch hold 170 includes a latch ledge 172 and three reboundledges 174, 176, and 178 (see FIG. 4). As shown in FIG. 4, the latchledge is formed complementarily to the shape of the latch pin 166. Thelatch assembly 140 further includes a base 180 and an actuator module500. Two springs 186 and 188 are positioned between the base 180 and thelatch hold 170 which is mounted by a pivot 190 to the carriage 124.

The actuator module 500, also shown in FIG. 4A, includes a plurality ofactuators 502 _(x) each of which include a respective actuator pin 504_(x). A loader 506 includes a plate 508 biased by a spring 510 intocontact with the actuators 502 _(x). The actuator 502 ₁ is positioned ina first actuating module position 512.

Operation of the table saw 100 is described with reference to FIGS. 1-5.Initially, the swing arm assembly 142 is maintained in a latchedposition with the latch pin 166 resting on the latch ledge 170 as shownin FIG. 5. In this position, the springs 188 and 186 are undercompression and exert a bias on the latch hold 170 about the pivot 190in a clockwise direction as viewed in FIG. 4. The latch hold 170 is thusbiased into contact with the lip 164 of the swing arm assembly 142 whichrestricts rotation of the latch hold 170.

Additionally, the blade wheel 156 is positioned sufficiently close tothe work-piece support surface 104 that the blade 108 extends above thework-piece support surface 104 as shown in FIG. 1. A user operates thebevel adjust turn wheel 112 to pivot the frame 114 with respect to thework-piece support surface 104 to establish a desired angle between theblade 108 and the work-piece support surface 104. The user furtheroperates the blade height adjustment turn-wheel 130 to move the carriage124 along the guiderails 126/128 to establish a desired height of theblade 108 above the work-piece support surface 104.

Using the switch 118, power is then applied to the motor 116 causing theoutput shaft 152 and the power wheel 150 to rotate. Rotation of thepower wheel 150 causes the belt 154 to rotate the blade wheel 156 andthe blade 108 which is mounted on the blade wheel 156. A work-piece maythen be shaped by moving the work-piece into contact with the blade 108.

The table saw 100 includes a sensing and control circuit (not shown)which activates the actuator 502 ₁ in response to a sensed condition.Any desired sensing and control circuit may be used for this purpose.One acceptable sensing and control circuit is described in U.S. Pat. No.6,922,153, the entire contents of which are herein incorporated byreference. The safety detection and protection system described in the'153 patent senses an unsafe condition and provides a control signalwhich, in the table saw 100, is used to actuate the actuator 502 _(x)positioned in a first actuating module position 512.

Upon actuation of the actuator 502 _(x), the actuator pin 504 _(x) isforced outwardly from the actuator 502 _(x). When the swing arm assembly142 is maintained in a latched position with the latch pin 166 restingon the latch ledge 170 as shown in FIG. 5, the strike plate 146 isaligned with the actuator 502 _(x) positioned in the first actuatingmodule position 512. Accordingly, as the actuator pin 504 _(x) is forcedout of the actuator 502 _(x), the actuator pin 504 _(x) impacts thestrike plate 146.

The shapes of the latch pin 166 and the latch ledge 172 are selectedsuch that the impact of the actuator pin 504 ₁ on the strike plate 146generates a force tending to push the latch pin 166 against the spring168. The spring constant of the spring 168 and the operatingcharacteristics of the actuator 502 _(x) are selected such that when theactuator pin 504 ₁ impacts the strike plate 146 the generated force issufficient to compress the spring 168 and to force the latch pin 166into a position whereat the swing arm assembly 142 is no longermaintained in position adjacent to the latch assembly 140 by the latchpin 166. In embodiments with a rigid latch pin 166, the generated forcecauses the latch hold 170 to rotate about the pivot 190 in acounterclockwise direction thereby forcing the springs 186 and 188 intofurther compression. When the latch hold 170 has rotated sufficiently,the latch ledge 172 moves out from underneath the latch pin 166.

In either event, the swing arm assembly 142 is no longer supported bythe latch hold 170. Consequently, the swing arm assembly 142 pivotsabout the power shaft 152 in the direction of the arrow 200 of FIG. 6such that the blade wheel 156 moves away from the work-piece supportsurface 104 through the position shown in FIG. 6 to the position shownin FIG. 7. Accordingly, the blade 108 is pulled by the swing armassembly 142 in a direction away from the work-piece support surface104.

Because the latch ledge 172 is formed complementarily to the shape ofthe latch pin 166, the wear of the latch ledge 172 and the latch pin 166during the de-latching described above is reduced. Accordingly, thepressure needed to effect de-latching does not change significantly overmultiple actuations of the actuator module 500.

As the swing arm assembly 142 moves in the direction of the arrow 200,the rebound plate 148 of the swing arm assembly 142 rotates below therebound ledge 178 of the latch hold 170. At this point, rotation of thelatch hold 170 about the pivot 190 is no longer restrained by the swingarm assembly 142. Accordingly, the springs 186 and 188 cause the latchhold 170 to rotate into a position whereat the rebound ledge 178 islocated in the swing path of the swing arm 142, that is, the path alongwhich the swing arm 142 moves, as shown in FIG. 7.

The configuration of FIG. 7 further shows the swing arm assembly 142rotated to a position whereat the swing arm assembly 142 contacts thestop pad 122. Accordingly, further rotation of the swing arm assembly142 in the direction of the arrow 200 of FIG. 6 is impeded by the stoppad 122. At this position, the blade 108 is completely located below thework-piece support surface 104. Therefore, an operator above thework-piece support surface 104 cannot be injured by the blade 108.

The stop pad 122 in this embodiment is a catcher assembly shown in FIG.4B which includes a housing 520, two rubber portions 522 and 524, and asand portion 526 positioned beneath the rubber portions 522 and 524. Asthe swing arm assembly 142 makes contact with the stop pad 122, theswing arm assembly 142 is wedged in between the rubber portions 522 and524 which are spaced to provide an interference fit. The interferencefit absorbs the kinetic energy of the swing arm assembly 142 and causesdeceleration of the swing arm assembly 142. The sand portion 526 absorbsresidual kinetic energy of the swing arm assembly 142 and brings theswing arm assembly 142 to a complete stop. The interference fit betweenthe rubber portions 522 and 524 and the swing arm assembly 142 alsosubstantially prevents the swing arm assembly 142 from reboundingupward. In other embodiments, a foam material such as “memory foam” maybe used in place of the sand portion 526.

When the condition resulting in actuation of the actuation module 500clears, the swing arm assembly 142 may be reset. The swing arm assembly142 is reset by moving the latch hold 170 out of the swing path. This iseffected by compressing the springs 188 and 186. The swing arm assembly142 may then be rotated in a counterclockwise direction about the outputshaft 152 until the rebound plate 148 is adjacent to the upper surfaceof the latch hold 170. The latch hold 170 is then released and thesprings 188 and 186 bias the latch hold 170 about the pivot 190 intocontact with the lip 164 of the swing arm assembly 142 which restrictsrotation of the latch hold 170. Additionally, the swing arm assembly 142is maintained in a latched position with the latch pin 166 resting onthe latch ledge 170 as shown in FIG. 5.

In the embodiment of FIG. 4A, each of the plurality of actuators 502_(x) is independently removable from the actuator module 500.Accordingly, after the actuator 502 ₁ has been actuated, a user removesthe expended actuator 502 ₁. Because the spring 510 is biasing theloader plate 508 toward the first actuator position 512, the actuator502 ₂ is automatically loaded into the first actuator position 512 uponremoval of the actuator 502 ₁. In one embodiment, movement of anactuator 502 _(x) into the first actuator position automatically forms aconnection (not shown) between the actuator 502 _(x) and the safetydetection and protection system. The table saw 100 is then ready forcontinued operation.

Other devices in addition to or in place of the stop pad 122 may be usedto limit rebound of the swing arm 124. By way of example, the springs186 and 188 bias the latch hold 170 to a location within the swing pathof the swing arm assembly 142.

Accordingly, any movement of the swing arm assembly 142 toward thework-piece support surface 104 brings the rebound plate 148 into contactwith the rebound ledge 178 as shown in FIG. 8. In the position of FIG.8, the blade 108 remains below the surface of the work-piece supportsurface 104 even after the swing arm assembly 142 rebounds off of thestop pad 122. Therefore, an operator above the work-piece supportsurface 104 cannot be injured by the blade 108.

The spring constants for the springs 186 and 188 are thus selected toensure that the latch hold 170 is positioned within the swing path ofthe swing arm assembly 142 before the swing arm assembly 142 travelsfrom the latched position downwardly into contact with the stop pad 122and then upwardly to a position whereat the blade 108 is above thework-piece support surface 104. Of course, the time available for movingthe latch hold 170 into the swing path can be increased by moving thestop pad 122 further away from the work-piece support surface 104 alongthe swing path. Such modification increases the overall height of theframe 114, particularly for embodiments with variable blade height. Theincreased material for the frame 114 results in increased weight.Increased size and weight are generally not desired for movable powertools. Thus, positioning the stop pad 122 closer to the work-piecesupport surface 104 along the swing path reduces the height of the frame114 and the resultant weight of the table saw 100.

For some embodiments wherein the stop pad 122 is positioned closer tothe work-piece support surface 104 along the swing path, such as theembodiment of FIG. 1, the distance between the swing arm assembly 142 inthe latched position and the stop pad 122 is such that the swing armassembly 142 contacts the stop pad 122 before the rebound plate 148rotates beneath the rebound ledge 178. Accordingly, the rebound ledges174 and 176 are provided at locations above the rebound ledge 178 tocontact the rebound plate 148 when the swing arm assembly 142 isactuated with the carriage 124 positioned closer to the stop pad 122 asdepicted in FIG. 9.

The angle and length of the stop pad 122 are selected in the embodimentof FIG. 2 to o ensure that the swing arm assembly 142 contacts the stoppad 122 at the foot 192 (see FIG. 3) regardless of the initial height ofthe carriage 124. Thus the foot 192 receives the force of the impactwhen the swing arm assembly 142 contacts the stop pad 122. Accordingly,while the materials used to form the foot 192, the strike plate 146, andthe rebound plate 148 are selected to absorb multiple impacts, lightermaterials may be used in other areas of the swing arm assembly 142 tominimize weight of the table saw 100.

In other embodiments, a friction ratchet assembly 600 as depicted inFIG. 10A is used to reduce rebounding of the swing arm 142. The frictionratchet assembly 600 includes a wheel 602, a spring 604, a firstfriction shoe 606, a second friction shoe 608, a wheel flange 610, afirst arm 612, and a second arm 614. The first friction shoe 606 iscoupled to the first arm 612. The second friction shoe 608 is coupledthe second arm 614. The wheel flange 610 is disposed between the firstand second friction shoes 606 and 608. The spring 604 applies a lightforce to the first and second friction shoes 606 and 608 to lightly makecontact with the wheel flange 610 when the swing arm assembly 142 ismoving downward (in a clockwise direction). Thus, upon initialactuation, the swing arm assembly 142 pivots about the power shaft 152and moves downwardly quickly.

During any counter-clockwise rotation of the swing arm assembly 142, thesecond arm 614 is forced inwardly generating an increasing amount offriction force between the first and second friction shoes 606 and 608and the wheel flange 610. This friction force quickly slows thecounter-clockwise rotation of the swing arm assembly 142, therebyreducing rebound of the swing arm assembly 142. Thus, the friction forceresists upward (counter-clockwise) movement of the swing arm assembly142 and prevents the blade 108 from traveling above the work-piecesupport surface 104.

In some embodiments, the actuators do not strike the swing arm assembly.By way of example, the table saw 650 of FIGS. 10B and 10C includes aswing arm 652, a spring 654, a lever catch 656, and an actuator 658. Thespring 654 can be a helical, compression, or a torsion spring. Thespring 654 is coupled to the swing arm assembly 652 and is configured tobe placed in its natural position, i.e., where the spring 654 is underminimal or reduced load, when the swing arm assembly 652 has reached itsmaximum downward (clockwise) travel. An actuator pin 660 of the actuator658 is normally in contact with the lever catch 656. The actuator pin660 is configured to slidably move the release lever 654 in and out ofcontact with the lever catch 656.

Accordingly, the swing arm 652 is rotated by the spring 654 when theactuator 658 is actuated and contact between the actuator pin 660 andthe lever catch 656 is removed. At the end of the clockwise travel, theswing arm assembly 652 tends to rebound in a counter-clockwise directionas described above. Any such rotation, however, results in loading ofthe spring 654. Therefore, upward (counter-clockwise) movement of theswing arm assembly 652 is prevented ensuring that the blade 108 does nottravel above the work-piece support surface 104.

In a further embodiment depicted in FIG. 10D, one or multiple coilsprings 670 are coupled to the swing arm assembly 672 on the lower sideof the swing arm assembly 672. The coil spring 670 as depicted in FIG.10D is in a loaded configuration. Upon activation of an activationmodule (not shown) the swing arm assembly 672 is released and, due tothe spring force of the coil spring 670, the swing arm assembly 672quickly moves downward (clockwise direction). At the end of theclockwise travel, the swing arm assembly 672 tends to rebound in acounter-clockwise direction. During the rebound the coil spring 672 isloaded. The spring constant of the spring 670 is selected to beover-damped throughout all possible latched swing arm positions.Therefore, upward (counter-clockwise) movement of the swing arm assembly672 that would expose a blade or other shaping device thereon (notshown) above a work-piece support surface (not shown) is prevented.

The table saw 100 thus actively monitors for an unsafe condition andinitiates mitigation action automatically in the event an unsafecondition is sensed. Additionally, movement and subsequent stopping ofthe swing arm assembly 172 is accomplished without requiring physicalcontact with the blade 108. Accordingly, the blade 108 is not damaged bythe mitigation action.

Moreover, because the mitigation action does not require interactionwith the blade 108, the mitigation system of the table saw 100 may beused with other shaping devices such as sanding wheels, blades withvarying dado blades, and molding head cutters, without requiring anymodification to the mitigation system. Additionally, because the movingcomponents of the mitigation system can be mounted on the frame 114, themitigation system can be used with any desired blade height or bevelangle.

The mitigation system discussed with respect to the table saw 100 can beimplemented using very light materials, and is thus amenable toincorporation into a variety of power tools including bench top saws andportable saws. For example, the components which are subjected toincreased stress within the mitigation system, such as the actuator pin504 _(x), the latch hold 170, the rebound plate 148, and the strikeplate 146, can be made of more durable materials including metals towithstand the impacts and stresses of activating the mitigation system.Other components, including the housings, may be fabricated from morelightweight materials to minimize the weight of the power tool.

If desired, the components of the table saw 100 may repositioned withinthe housing 102. By way of example, FIG. 10E depicts a power tool 202with a latch pin 204 positioned within a base 206. The latch pin 204 isbiased by a spring (not shown) toward a latch hold 208 which ispivotably mounted by a pivot 210 to a swing arm assembly 212. In thisembodiment, the latch hold 208 includes a latch ledge 214 and a singlerebound ledge 216. The base 206 includes a rebound plate 218. Anadditional rebound plate 220 is provided on the base 206 as a safetymeasure in the event the latch hold 208 does not move with the designedspeed in a manner similar to the latch hold 170. Operation of the powertool 202 as configured in the manner of FIG. 10E is substantiallyidentical to operation of the table saw 100 as configured in FIG. 4.

A further example of rearranged components is shown in FIG. 11, whereina power tool 230 includes a swing arm assembly 232 mounted vertically ona carriage assembly 234 below a slot 236 in a work support surface 238.The power tool 230 further includes an actuator 240 and a rebound latch242, both of which are also mounted to the carriage assembly 234. Theswing arm assembly 232 includes a power wheel 244 which rotates a bladewheel 246 through a belt 248. The swing arm assembly 232 furtherincludes a strike plate 250 and a latch plate 252.

The swing arm assembly 232 is maintained in the position shown in FIG.11 by a latch pin 254. The latch pin 254 is biased by a spring 256 intoa latch recess 258 in the swing arm assembly 232. The pin 254, alsoshown in FIG. 12, includes a head 260 and a body 262. A bore 264 extendsthrough the body 262 and includes an actuation ramp 266. The surface ofthe actuation ramp 266 is angled from an upper portion 268 of the bore264 to a lower portion 270 of the bore 264.

The rebound latch 242 is pivotably mounted to the carriage assembly 234by a pivot 272. A spring 274 biases the rebound latch 242 in a counterclockwise direction as viewed in FIG. 11. The rebound latch 242 includesa rebound ledge 276, a release 278, and a latch foot 280. A stop pad 282is also mounted to the carriage assembly 234.

Operation of the power tool 230 may be substantially identical tooperation of the table saw 100 through the firing of the actuator 240.When the actuator 240 is actuated, however, an actuator pin 290, shownin FIG. 13, is forced outwardly from the actuator 240 into contact withthe actuation ramp 266. The shape of the actuator pin 290 and theactuation ramp 266 forces the latch pin 254 against the spring 256. Theforce transferred from the actuator 240 is sufficient to overcome thebias of the spring 256. Accordingly, the spring 256 is compressed andthe pin 254 moves outwardly from the latch recess 258 to the positionshown in FIG. 14.

In FIG. 14, the latch pin 254 has moved to a position whereat the strikeplate 250 of the swing arm assembly 232 is exposed to the actuator pin290 through the lower portion 270 of the bore 264. Additionally, thehead 260 of the latch pin 254 has been moved to a position whereatrotation of the swing arm assembly 232 is not inhibited by the latch pin254, even though a portion of the latch pin 254 may remain within therecess 258.

Continued movement of the actuator pin 290 outwardly from the actuator240 causes the actuator pin 290 to contact the strike plate 250 asdepicted in FIG. 15. The actuator pin 290 transfers sufficient force tothe strike plate 250 to cause the swing arm assembly 232 to rotate aboutthe power wheel 244 in a manner similar to the rotation of the swing armassembly 142 described above. Rotation of the swing arm assembly 232brings the swing arm assembly 232 into contact with the release 278 ofthe rebound latch 242 as shown in FIG. 16. The force of the swing armassembly 232 is sufficient to overcome the bias of the spring 274thereby rotating the rebound latch 242 about the pivot 272 in thedirection of the arrow 284.

Once the rebound latch 242 has rotated sufficiently, the swing armassembly 232 slides past the release 278 and into contact with the latchfoot 280 as shown in FIG. 17. Continued rotation of the swing armassembly 232 forces the latch foot 280 downward, causing the reboundlatch 242 to rotate in the direction of the arrow 286 of FIG. 17. As therebound latch 242 rotates in the direction of the arrow 286, the reboundledge 276 is rotated into a position above the latch plate 252 as shownin FIG. 18.

The swing arm assembly 232 then rotates into contact with the stop pad282. In the event the swing arm assembly 232 begins to rebound off ofthe stop pad 282, the latch plate 252 moves into contact with therebound ledge 276 and rotation of the swing arm assembly 232 isarrested.

The vertical arm configuration of the tool 230 may be desirable inapplications wherein injury is most likely to occur as a result ofmovement parallel to the surface of the work-piece support surface. Byway of example, FIG. 19 is a schematic of a work-piece support surface300 with a shaping device 302 extending above the surface of thework-piece support surface 300. The shaping device 302 rotates about anaxis defined by a blade wheel 304. In a horizontal swing armconfiguration, the blade wheel 304 is driven by a power shaft 306. In avertical swing arm configuration, the blade wheel 304 is driven by apower shaft 308.

A work-piece, for purpose of this example, is moved by a user toward theblade 302 in the direction of the arrow 310. Thus, the point at whichthe user is most likely to come into accidental contact with the shapingdevice 302 is at or near the location 312. When accelerated such as byan actuator 182, the blade wheel 304, in a horizontal swing armconfiguration, rotates from the position indicated by the blade wheel304 to the position indicated by the blade wheel 304 _(H1) in a firsttime interval. The location of the shaping device 302 associated withthe blade wheel 304 _(H1) is blade 302 _(H1). Thus, the blade 302 hasmoved from the location 312 to the location 314.

During the same time interval, the blade wheel 304, in a vertical swingarm configuration, rotates from the position indicated by the bladewheel 304 to the position indicated by the blade wheel 304 _(V1). Thelocation of the shaping device 302 associated with the blade wheel 304_(V1) is blade 302 _(V1). Thus, the blade 302 has moved from thelocation 312 to the location 316. Accordingly, the blade 302 is movedfarther away from the contact point 312 by the vertical configurationthan by the horizontal configuration.

Likewise, the blade wheel 304, in a horizontal swing arm configuration,rotates from the position indicated by the blade wheel 304 _(H1) to theposition indicated by the blade wheel 304 _(H2) in a second timeinterval. The location of the shaping device 302 associated with theblade wheel 304 _(H2) is blade 302 _(H2). Thus, the blade 302 has movedfrom the location 312 to the location 316 over two time intervals.

During the second time interval, the blade wheel 304, in a verticalswing arm configuration, rotates from the position indicated by theblade wheel 304 _(V1) to the position indicated by the blade wheel 304_(V2). The location of the shaping device 302 associated with the bladewheel 304 _(V2) is blade 302 _(V2). Thus, the blade 302 has moved fromthe location 312 to the location 318. Accordingly, the blade 302 movesaway from the contact point 312 by about a factor of two in the verticalconfiguration as compared to the horizontal configuration.

Thus, in applications wherein an injury is most likely to occur at oneside of the shaping device, a vertically oriented swing arm may be usedto mitigate injury. Most table saw applications will fit into thisscenario if a blade guard is installed. FIG. 19 similarly illustratesthat the horizontal swing arm configuration moves the blade downwardlyat a faster rate. Thus, in applications wherein the injury is mostlikely to occur at the top of the shaping device, a horizontal swing armconfiguration may be used to mitigate injury.

As described above, operation of the latch pin 254 is significantlydifferent from operation of the latch pin 166. Specifically, the latchpin 166 is operated by applying a force to the swing arm assembly 142.In contrast, the latch pin 254 is relatively immune to activation byapplication of force to the swing arm assembly 232. Accordingly, thelatch pin 254 is a positive locking mechanism that is not susceptible tounintentional unlocking absent complete failure of the latch pin 254.The latch pin 254 may thus be used in swing arms that are positioned inany desired orientation.

A variety of positive locking mechanisms, i.e., mechanisms wherein alatch is moved prior to application of rotational force to the swing armassembly, may be incorporated into power tools. One example of anotherpositive locking mechanism is the latch pin 320 of FIG. 20. The latchpin 320 includes a head 322 and a body 324. The latch pin 320 furtherincludes an actuation ramp 326 within a bore 328. While the latch pin320 is similar to the latch pin 254, the body 324 of the latch pin 320is substantially wider than the cylindrical body 262 of the latch pin254. Thus, the bore 328 of the latch pin 320 is easily maintained inalignment with an actuator pin. Additionally, a non-cylindrical bodysuch as the body 324 may provide enhanced alignment of the swing armwith which the body 324 is used.

Another positive locking mechanism is the latch pin 330 of FIG. 21. Thelatch pin 330 includes a head 332 and a body 334. The body 334 may beany desired shape including rectangular or cylindrical. The latch pin330 further includes an actuation ramp 336 within a bore 338. The latchpin 330 also includes a wheel 340 rotatably mounted in the head 332. Thewheel 340 reduces wear on the latch pin 330. Additionally, the wheel 340in this embodiment is configured to contact only one side of a recess342 in a swing arm 344. Accordingly, by providing another member whichlimits the upward or counter-clockwise travel of the swing arm 344, thewheel 340 is used to “pinch” the swing arm 344 to reduce or eliminateundesired movement of the swing arm 344.

Another positive locking mechanism is the latch pin 360 of FIG. 22. Thelatch pin 360 includes a head 362 and a body 364. The body 364 may beany desired shape including rectangular or cylindrical. The latch pin360 further includes an actuation ramp 366 within a bore 368. The head362 in this embodiment is configured to contact opposing tapered sidesof a recess 370 in a swing arm 372. Accordingly, seating of the head 362in the recess 370 eliminates undesired movement of the swing arm 372.Further reduction in non-axial movement of the latch pin 360 whilepermitting axial movement for locking and unlocking the swing arm 372 isprovided by oil impregnated bushings 374.

A positive locking mechanism may also be provided in the form ofrotating latch pin such as the latch pin 380 depicted in FIGS. 23 and24. The latch pin 380 includes a head 382 and a body 384. The latch pin380 further includes an actuation ramp 386 extending from the body 384.The head 382 includes a hook portion 388 which engages a retaining pin390 in a swing arm 392. The latch pin 380 is pivotably supported by apivot pin 394 and biased toward the retaining pin 390 by a spring 396.When the hook portion 388 engages the retaining pin 390, the actuationramp 386 is aligned with an actuator pin 398.

In operation, movement of the actuator pin 398 causes the actuator pin398 to impinge the actuation ramp 386 of the latch pin 380 imparting arotational force to the latch pin 380. The actuation ramp 386 thusconverts axial force from the actuator pin 398 to a rotational force.The rotational force overcomes the bias of the spring 396 causing thelatch pin 380 to rotate in a counterclockwise direction about the pivotpin 394. The shape of the hook portion 388 and the retaining pin 390along with the location of the hook portion 388 relative to the pivotpin 394 is selected to ensure that an upward force is not imparted ontothe retaining pin 390 from the latch pin 384 during this rotation. Oncethe actuation ramp 386 has rotated sufficiently, the actuator pin 398continues to move axially into contact with the swing arm 392.

The latch pin 400 depicted in FIGS. 25 and 26 is another positivelocking mechanism in the form of rotating latch pin. The latch pin 400includes a head 402 and a body 404. The latch pin 400 further includesan actuation ramp 406 extending from the body 404. The head 402 includesa lip portion 408 which engages a retaining recess 410 in a swing arm412. The latch pin 400 is pivotably supported by a pivot pin 414 andbiased toward the retaining recess 410 by a spring 416. When the lipportion 408 engages the retaining pin 410, the actuation ramp 416 isaligned with an actuator pin 418.

In operation, movement of the actuator pin 418 causes the actuator pin418 to impinge the actuation ramp 406 of the latch pin 400 imparting arotational force to the latch pin 400. The rotational force overcomesthe bias of the spring 416 causing the latch pin 400 to rotate in aclockwise direction about the pivot pin 414. The shape of the lipportion 408 and the retaining recess 410 along with the location of thelip portion 408 relative to the pivot pin 414 is selected to ensure thatan upward force is not imparted onto the retaining recess 410 from thelatch pin 404 during this rotation. Once the actuation ramp 406 hasrotated sufficiently, the actuator pin 418 continues to move axiallyinto contact with the swing arm 412.

The actuator pin 418 in this embodiment impinges a strike plate portion420 which is pivotably attached to a lower swing arm housing 422 by apivot pin 424. Spring washers 426 positioned between the strike plateportion 420 and the lower swing arm housing 422 bias the strike plateportion 420 into a position aligned with the actuator pin 418 when thelip portion 408 is within the retaining recess 410. When the actuatorpin 418 impacts the strike plate portion 420, the spring washers 426 arecompressed thereby reducing the peak force that is transferred from thestrike plate portion 420 to the other components of the swing arm 412.This allows lighter materials to be used for some components of theswing arm 412 while ensuring a rapid acceleration of the swing arm 412.

The latch pin 430 depicted in FIGS. 27 and 28 is another positivelocking mechanism in the form of rotating latch pin. The latch pin 430includes a head 432 and a body 434. The latch pin 430 further includesan actuation ramp 436 extending into the body 434. The head 432 includesa lip portion 438 which engages a retaining recess 440 in a swing arm442. The latch pin 430 is pivotably supported by a pivot pin 444 andbiased toward the retaining recess 440 by a radial spring 446. When thelip portion 438 engages the retaining pin 440, the actuation ramp 446 isaligned with an actuator pin (not shown). If desired, a second latchpin, substantially identical to the latch pin 430, may be provided inopposition to the latch pin 430.

In operation, movement of the actuator pin (not shown) causes theactuator pin (not shown) to impinge the actuation ramp 436 of the latchpin 430 and the axial force is translated into a rotational force by theactuating ramp 436 imparting a rotational force to the latch pin 430.The rotational force overcomes the bias of the spring 446 causing thelatch pin 430 to rotate in a clockwise direction about the pivot pin 444and outwardly from the swing arm 442. Once the actuation ramp 436 hasrotated sufficiently, the actuator pin (not shown) continues to moveaxially into contact with a strike plate 448 on the swing arm 412.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, the same should be considered asillustrative and not restrictive in character. It is understood thatonly the preferred embodiments have been presented and that all changes,modifications and further applications that come within the spirit ofthe invention are desired to be protected.

1. A table saw comprising: a work-piece support surface; a swing armassembly movable along a swing path between a first swing arm positionwhereat a portion of a shaping device supported by the swing armassembly extends above the work-piece support surface and a second swingarm position whereat the portion of the shaping device does not extendabove the work-piece support surface; a latch pin pivotable between afirst position whereat the latch pin is engaged with the swing armassembly and a second position whereat the latch is not engaged with theswing arm assembly; an actuator module configured to receive a pluralityof actuators; a first actuating module position within the actuatormodule configured to align a first of the plurality of actuators with astrike plate on the swing arm assembly; a loader configured to bias asecond of the plurality of actuators from a second actuating moduleposition within the actuator module toward the first actuating moduleposition; and a control system configured to actuate each of theplurality of actuators positioned in the first actuating module positionso as to cause the latch pin to move from the first position to thesecond position and to force the swing arm assembly away from the firstswing arm position and toward the second swing arm position.
 2. Thetable saw of claim 1, wherein: the actuator module comprises a spring.3. The table saw of claim 1, wherein each of the plurality of actuatorscomprises a pyrotechnic device.
 4. The table saw of claim 1, wherein theactuator module is removably supported beneath the work-piece supportsurface.
 5. The table saw of claim 1, wherein each of the plurality ofactuators is independently removable from the actuator module.
 6. Apower tool comprising: a work-piece support surface; a swing armassembly movable along a swing path between a first swing arm positionwhereat a portion of a shaping device supported by the swing armassembly extends above the work-piece support surface and a second swingarm position whereat the portion of the shaping device does not extendabove the work-piece support surface; a latch pin movable between afirst position whereat the latch pin is engaged with the swing armassembly and a second position whereat the latch is not engaged with theswing arm assembly; an actuator module configured to receive a pluralityof actuators; a first actuating module position within the actuatormodule configured to align a first of the plurality of actuators with aportion of the swing arm assembly; a loader configured to bias a secondof the plurality of actuators from a second actuating module positionwithin the actuator module toward the first actuating module position;and a control system configured to actuate each of the plurality ofactuators positioned in the first actuating module position so as tocause the latch pin to move from the first position to the secondposition and to force the swing arm assembly away from the first swingarm position and toward the second swing arm position.
 7. The power toolof claim 6, wherein: the actuator module comprises a spring.
 8. Thepower tool of claim 6, wherein each of the plurality of actuatorscomprises a pyrotechnic device.
 9. The power tool of claim 6, whereinthe actuator module is removably supported beneath the work-piecesupport surface.
 10. The power tool of claim 6, wherein each of theplurality of actuators is independently removable from the actuatormodule.